CQI-9 3rd Edition AMP 041019
CQI-9 3rd Edition AMP 041019
CQI-9 3rd Edition AMP 041019
Process Table E
Annealing No
Normalizing No
Stress-Relieving No
Process Table F
Low Pressure Carburizing No
Process Table G
Sinter Hardening No
Process Table G
Ion Nitriding No
IATF 16949:2016, IATF Certificate Number 0284226, Certificate Number 5465; ISO
Current Quality Certification(s):
9001:2015, Certificate Number 5466
Date of Re-assessment (if necessary):
Personnel Contacted:
Name: Title: Phone: Email:
George Baloi 586-757-7337, x-107 george@ampht.com
Quality Mgr
Internal Auditors/Assessors:
Name: Company: Phone: Email:
Assessment
Assessment
To ensure all customer requirements are both understood and satisfied, the
organization shall have all related heat treat and customer referenced
standards and specifications available for use and a method to ensure that
All related heat treat and customer-referenced standards and specifications
they are current. Such standards and specifications include, but are not
Are all heat treat related and are available for use and viewing via AMP's own Intranet. These standards
limited to, those relevant documents published by SAE, AIAG, ASTM, ISO,
referenced specifications and specifications are requested from the customers at the time of quotation
EN, JIS, General Motors, Ford, and Chrysler. The organization shall have a
current and available? For of the parts, are scanned into the electronic database within one week, and
process to ensure the timely review, distribution, and implementation of all
example: Industry and are available for viewing or printing on the AMP Intranet. Updates to
customer and industry engineering standards / specifications and changes
1.5 customer specific referenced standards and specifications are usually obtained from X
based on customer-required schedule. Timely review should be as soon as
specifications such as SAE, customers, reviewed at AMP Staff/Quality Meetings for possible impact on
possible and shall not exceed two working weeks. The organization shall
AIAG, ASTM, ISO, EN, JIS, processes and implementation timetables, and then scanned into the
document this process of review and implementation, and it shall address
General Motors, Ford, and electronic database within one week of receipt, for viewing availability on the
how customer and industry documents are obtained, how they are
Chrysler. AMP Intranet. The Quality Department is responsible for performing these
maintained within the organization, how the current status is established, and
tasks.
how the relevant information is cascaded to the shop floor within the two-
week period. The organization shall identify who is responsible for
performing these tasks.
The heat treater shall have written process specifications for all active
processes and identify all steps of the process including relevant operating
parameters. Examples of operating parameters include process
temperatures, cycle times, load rates, atmosphere or gas flow settings, belt
Is there a written process Computer-based recipes for each part number include all process
speeds, quench agitation speeds, etc. Such parameters shall not only be
1.6 specification for all active parameters, including process steps, tolerances, specifications, cycle times, X
defined, they shall have operating tolerances as defined by the organization
processes? gas flows, and process temperatures.
in order to maintain process control.
All active processes should have a written process specification.
These process specifications may take the form of work instructions, job
card, computer-based recipes, or other similar documents.
Historical Surface Hardness data for each part (last 5 Work Orders
The analysis of products and processes over time can yield vital information
processed) is displayed on each Work Order, including steel chemistry
Does the heat treater collect for defect prevention efforts. The organization shall have a system to collect,
information (assumed or as supplied by Customer), Surface Hardness (Min
and analyze data over time, analyze, and react to product or process data over time. Methods of
1.8 & Max) out of Quench, Tempering Temperature, and Surface Hardness (Min X
and react to this data? analysis shall include ongoing trend or historical data analysis of product or
& Max) out of Temper. Surface Hardness and Tempering Temperature
process parameters. The organization shall determine which parameters to
historical data helps our associates to determine the best tempering
include in such analysis.
temperature for current Work Order.
Assessment
The OEM shall be notified when parts are reprocessed in the heat treat
operation. It is preferred that the notification be on a case-by-case basis.
However, it is understood that some reprocessing (such as but not limited to
re-tempering operations) may be pre-approved during the APQP or PPAP
phase. To be pre-approved for reprocessing, the heat treater shall meet the The OEM customer is notified when parts are reprocessed in the heat treat
following requirements: operation, on a case-by-case basis. However, Retempering is normally not
• The heat treater shall submit for approval by the OEM customer the considered as reprocessing or rework, so customer notification for
reprocessing procedure and this procedure shall be referenced in the heat Retempering is a rare occurrence. A Quality Procedure for Reworking /
treater’s FMEA and process control plan Reprocessing is documented and in place, including special Yellow Rework
Is the OEM customer notified
1.11 • The procedure shall describe product characteristics for which Form, issued, filled out, and signed by designated qualified technical X
when parts are reprocessed?
reprocessing is permissible as well as those characteristics for which personnel. Complete record documentation is kept of each Rework and the
reprocessing is not permissible. Rework Information is tracked and translated into several different Metrics
• Any reprocessing activity shall require a new processing control sheet by AMP, primarily to confirm the continuous reduction in number of Reworks
issued by qualified technical personnel denoting the necessary heat treat and the reduction in the percentage of Reworks against the total Work
process modifications. Orders processed.
• Records shall clearly indicate when and how any material has been
reprocessed.
• The Quality Manager or a designee shall authorize the release or
reprocessed product.
The heat treater shall define a process for continual improvement for each
Is there a continual heat treat process identified in the scope of the HTSA. The process shall be
Continual improvement plans focus on the highest occurring problems in
improvement plan applicable to designed to bring about continual improvement in quality and productivity.
1.13 Quality and Productivity, with quarterly reporting on the various metrics, X
each process defined in the Identified actions shall be prioritized and shall include timing (estimated
including trend lines to gauge the effectiveness of the problem resolutions.
scope of the assessment? completion dates). The organization shall show evidence of program
effectiveness.
Assessment
The organization shall provide employee training for all heat treating
operations. All employees, including backup and temporary employees,
On-The-Job Material Handler and Heat-Treater training and qualification
Is management providing shall be trained. Documented evidence shall be maintained showing the
program is utilized. The AMP Training Matrix lists all personnel qualifications
1.16 employee training for heat employees trained and the evidence shall include an assessment of the X
and training that was successfully completed, as well as any training still in
treating? effectiveness of the training. Management shall define the qualification
process.
requirements for each function, and ongoing or follow-up training shall also
be addressed.
Is there a responsibility matrix The organization shall maintain a responsibility matrix identifying all key
to ensure that all key management and supervisory functions and the qualified personnel who
A Responsibility Matrix is part of the Quality Management System and is
1.17 management and supervisory may perform such functions. It shall identify both primary and secondary X
available for viewing and review on the AMP Intranet.
functions are performed by (backup) personnel for the key functions (as defined by the organization).
qualified personnel? This matrix shall be readily available to management at all times.
Is material from different steel When different steel mill heats or metals are indicated on the incoming
mill heats or metals which may Different steel mill heats or metals which require different heat treat orders, and they are not separated, but indicate that they should be
preclude achieving the parameters, such as but not limited to, austenitizing, quenching, or tempering processed separately, the order is placed on hold and the Customer is
1.20 X
specified metallurgical times and/or temperatures shall be processed separately in order to achieve contacted for the Customer's final disposition. The final disposition is
properties prevented from specified metallurgical properties. noted/written on the incoming order, with the date and name of the
being processed together? authorizing Customer who provided the final disposition.
Assessment
Is lot traceability and integrity Out-going lot(s) shall be traceable to the incoming lot(s). The discipline of Lot identification is linked to the AMP Work Order number, which is unique
2.3 maintained throughout all precisely identifying lots and linking all pertinent information to them for each order. All information is stored in AMP's WORP computer system X
processes? enhances the ability to do root cause analysis and continual improvement. database.
Heat-treating furnaces and other processing equipment contain areas that Alternating the processing of larger parts and smaller parts helps to minimize
Is there a system to identify have a risk of trapping or holding parts. Such trapping of parts can lead to mixing and makes sorting easier if mixing does occur. Large gap times
trap points in the entire heat damage, improperly processed parts or lot mixing/contamination. A system between orders also reduce the risk of mixed parts. Chasers are placed at
treat process to reduce risk of shall exist to identify trap points in the entire heat treat process to reduce risk the end of orders to "bump" or "force" material out of the furnace and these
2.5 X
mixed parts (inappropriate, non- of mixed parts (inappropriate, non-heat treated, or improperly heat treated chasers also serve to signify the end of the current order of material in the
heat treated, or improperly parts). The heat treater shall have documented procedures to identify and furnace. Trap points in the heat treat process have been identified and
heat treated parts)? monitor trap points for each process/equipment. Monitoring of potential trap action plans developed and implemented to monitor and minimize the
points shall occur for every part changeover. potential impact of those trap points on product being processed.
Containers handling customer product shall be free of inappropriate material. Customer containers are rotated and flipped over to loosen and remove
After emptying and before re-using containers, containers shall be inspected possible trapped parts, in the dumping station. Each container is also
Are containers free of to ensure that all parts and inappropriate material have been removed. The visually inspected for foreign and trapped material. AMP's in-house
2.6 X
inappropriate material? source of inappropriate material shall be identified and addressed. This is to processing containers (Roura hoppers) are free of seams that could trap
ensure that no nonconforming heat treated parts or inappropriate material inappropriate material. The relevant AMP documents are titled "Container
contaminate the finished lot. Handling Process" and "Dropped Parts Policy".
Assessment
Furnace loading parameters shall be specified, documented, and controlled. Furnace loading parameters are specified in the electronic recipes,
Is furnace loading specified,
2.7 Examples include feed rate, belt speed, number of parts per fixture, and controlled by electronic feeders, and printed out on the hard copies of the X
documented, and controlled?
load weight. Refer to Process Tables, Section 3.0, for frequency of checks. Work Orders.
Assessment
Are In-Process / Final Test Testing frequencies meet or exceed specifications. See individual Work
In-Process / Final Test Frequencies shall be performed as specified in
2.15 Frequencies performed as Order instructions and Work Orders for actual Test Frequencies for each X
Process Tables. Refer to Process Tables, Section 4.0.
specified in Process Tables? order.
Assessment
Section 3 - Equipment
The heat-treat equipment including furnaces, generators, and quench
All furnace lines, generators, and quench systems have proper Process
Do furnaces, generators, and systems shall have proper process controls and related equipment.
Controls and are Monitored continuously via our Electronic Monitoring / Data
3.1 quench systems have proper Examples include temperature, carbon potential/dew point, gas flows, X
Acquisition System. Agitation is not electronically monitored, but is
process control equipment? quench monitoring system including agitation, temperature control, etc. as
monitored via Furnace Logs.
listed in the applicable Process Tables, Section 1.0.
Are process equipment The calibration and certification of the process equipment shall be checked
3.2 calibrations and/or verification at regular specified intervals. Refer to the applicable Process Tables, Yes, per Table A, section 1.0 and 2.0 specified frequencies. X
certified, posted, and current? Sections 1.0 and 2.0, for equipment calibration or certification time tables.
Are thermocouples & The thermocouples and protection tubes shall be checked or replaced in
Thermocouples are checked quarterly by an outside service, based on a
3.3 protection tubes checked or compliance to a preventive maintenance schedule. Refer to the applicable X
preventive maintenance schedule.
replaced per Process Tables? Process Tables, Section 2.0.
Temperature uniformity surveys shall be conducted per the requirements in AMP's Rotary Furnaces: Temperature Uniformity Surveys (TUS) are
the applicable Process Tables, Section 2.0. Certain furnace designs, e.g., conducted per the requirements in the applicable Process Tables, Section
Are temperature uniformity
rotary retorts & some continuous pusher furnaces preclude direct 2.0 , Year-long Property Studies are also being conducted, using high-
surveys performed per
3.4 temperature profiles. Alternate test methods per Section 3.4.5 are volume / frequently-processed parts, on each furnace, using Standard X
requirements in Process
acceptable for furnaces where temperature uniformity studies are not Deviation and Mean of Surface Hardness results, to evaluate and analyze
Tables?
possible. TUS studies are not required for Ion Nitriding. Refer to Process the performance and the effectiveness of the performance of each furnace.
Table H Item # H2.4 for specific requirements. TUS is performed for tempering furnaces.
The heat treater shall have a list of heat treat process and equipment alarms
that, if not properly working, may have a high probability of producing non-
conforming product. These alarms shall be checked quarterly at a minimum
Are the process & equipment or after any repair or rebuild.
System alarms are checked for proper function monthly (and after any repair
3.6 alarm checks being tested for X
or rebuild) and documented in the Preventive Maintenance log.
proper function? Other alarms, including but not limited to safety-related, shall be checked per
heat treater's requirement.
Assessment
When the back-up verification check of the atmosphere does not correlate
within pre-established limits with the primary control method (carbon
A back up verification of the potential/dew point reading), the heat treater shall resolve the out-of-limit
atmosphere is required. When discrepancy. The back-up atmosphere monitoring system reading and the
the back-up verification check automatically controlled atmosphere dew point/carbon potential reading shall
of the atmosphere does not be maintained within the correlation limits specified in the control plan or
correlate within pre-established internal procedures. These range tolerances vary with the specific heat treat
limits with the primary control process and the equipment used. Shift Supervisors, Operations, and Lab Personnel resolve all atmosphere
method (carbon potential/dew The heat treater shall make appropriate technical adjustments and then re- problems, using one or more of the primary control methods, including a
point reading), is correlation of establish/demonstrate the correlation of the actual atmosphere carbon portable 3-Gas Analyzer available for verification of the atmosphere and a
3.8 X
the carbon-bearing potential/dew point reading to the primary control and back-up atmosphere portable DP analyzer (DP2000). Key associates are trained in the use of the
atmosphere to the primary reading. The range tolerances for correlation between the two readings 3-Gas Analyzer/DP Analyzer for use in checking atmosphere, allowing a
control method re-established? shall be in the control plan or internal procedures. The back-up carbon backup/verification of the actual atmosphere Dewpoint readings.
potential/dew point reading shall be established using one or more of the
NOTE: This requirement is following methods:
specific to Process Tables A, • Carbon bar, slug, or surface carbon of part
B, E, F, and G; Sections 1.0 • Shim stock
and 3.0. • 3-gas analyzer
• Dew point
• Hot wire resistance
Assessment
Ammonia pick-up can be undesirable in parts and heat treat processes not
specifying/requiring ammonia as an addition.
Is there a minimum of 3 hour The heat treater shall perform a minimum 3 hour purge prior to processing
A minimum 3-hour oxiding burn-out is performed prior to processing product
purge of the furnace product not requiring ammonia as an addition. Reduction of 3 hour purge
not requiring ammonia as an addition. End times for previous process (and
atmosphere when switching requires conclusive test data of the atmosphere to show no significant
3.10 part processed) are recorded, as well as the start time for the next process X
from an ammonia bearing amount of residual ammonia is present in the furnace atmosphere.
(and the specific part processed). The Furnace Log also records the start
atmosphere to a non-ammonia
and end times for the burn-out.
bearing? Log book, data logger, or other records shall document the actual purge time
and that sufficient time has been allocated to remove ammonia from the
furnace prior to processing parts in heat treat processes not specifying
ammonia.
In absence of a rigorous fail- AMP has computer-controlled feeder systems to ensure that parts are
3.12 The infrared temperature pyrometers are required at the exit end of X
safe, are all continuous belt uniformly loaded into the furnaces.
continuous belt furnaces to monitor for under temperature parts. The
furnaces equipped with sight
temperature alarm shall be within 28oC (50oF) of the furnace set point
glass inspection ports and
temperature. Results shall be strip charted or continuously data logged.
infrared temperature
Infrared temperature pyrometers shall be calibrated annually at a minimum
pyrometers at discharge end of
and certified. All sight glasses shall be cleaned per the preventive
the hardening furnace?
maintenance schedule.
The heat treater shall periodically have the quenching medium analyzed for
specific quenching characteristics, e.g., cooling curve, water content, salt
concentration, as specified in the applicable Process Tables, Section 5.0.
This does not include Process Table G & H.
Is the quenching medium The quenching media (oil) is analyzed quarterly, while the water quench
3.14 • The quench media characteristic tolerances shall be specified by the X
analyzed? media is analyzed every six months.
quench medium supplier or the heat treater.
• Analysis shall be reviewed for conformance by the heat treater. This
review shall be documented.
Assessment
The heat treater shall control the energy or power for each part.
• A signature monitor for each machine is preferred. A signature monitor
Does the heat treater control gives the energy unit (voltage, kilowatt, etc.) vs. time or distance (for
3.16 the energy or power for each scanning systems). X
part? • An energy monitor or equivalent is acceptable if approved by the
authorized customer representative.
The heat treater shall have a coil management system. Coil refers to the
Does the supplier have a coil heating coil and the quench plenum.
management system? Coil • Spare coils for each part shall be available on-site.
3.17 X
refers to the heating coil and • Coils shall conform to the approved original design.
the quench plenum. • Engineering change approval from the customer is required whenever the
coil design is changed.
After downtime of the induction heating system, air pockets may form in the
quench lines. These air pockets will cause interrupted quenching at start-up.
Is there a procedure to purge
The Heat treater shall establish the time limit (of the downtime) when this
3.21 the air pockets from the X
procedure is to be followed. [Example: The quench lines shall be purged
quench lines?
after induction heating system is down greater than 4 hours.] Factors such
as quench line diameter, length, geometry, etc. shall be considered.
Related
Question Customer or Internal Job (Shop) Order or Reference Documentation Pass / Fail
Job Audit Question HTSA Actual Condition (Objective Evidence)
# Requirement Requirement / N/A
Question #
4.1 Are contract review, advance 1.2 Internal and Customer RFQ and Team Feasibility for each part. Generic RFQ, Team Feasibility, APQP, PFMEA Pass
quality planning, FMEA, control 1.3 PFMEA for each process. Control Plans for each performed by designated and qualified
plans, etc., performed by 1.4 part are integrated into electronic recipes. These individuals - electronic signoff of Team
qualified individuals? 1.17 are created and maintained by qualified Feasibility for PN XXXX is evident in
individuals. WORP.
4.2 Does the heat treat facility 1.5 Internal and Customer Material specifications and customer Copies of Customer Material Steel Certs Pass
have the customer specifications and requirements are listed on are not supplied by Customer; Customer
specifications for the part? customer drawings/specifications and transferred product specifications & Material are on
to the specific part recipe. Customer Spec (and PO), which is
viewable on AMP WORP software, & are
listed on Work Order/recipe.
4.3 Is a shop traveler created to 1.6 Internal Work Order is created electronically, along with a Work Order in WORP, along with a hard Pass
meet customer requirements? 2.1 hard copy for the Shop Floor. copy on shop floor and AMP router tag.
4.4 Is material identification (part 2.2 Internal and Customer Lot #, Heat #, Material chemistry if available are Carbonitriding, Quench Media Oil, PN Pass
numbers, lot numbers, heat 2.3 on AMP WO. A part photo and customer PN are XXXX, part photo, PO#15368, Shipper
numbers, contract numbers, 2.4 on AMP WO and Router Tags, WO # & # of tubs 6382, Lot#6382, Material Chemistry not
etc.) maintained throughout the are on the magnetic tag. provided, & # of tubs are listed on WO.
heat treat process? Carbonitriding, Quench Media Oil, WO#,
PN, Customer, part photo, Lot #, and # of
tubs are on the router tag. WO # & # of
tubs are on the magnetic tag.
4.5 Is there documented evidence 2.1 Internal requirement to AMP Receiving Inspection Procedure requires Parts weighed in & part #, weight, Pass
of Receiving Inspection? check part ID, tub ID, tub visual inspection of parts and customer container container #, & general condition are
weight, and quantity at as received. AMP Quality Dept is notified if an recorded & compared to Customer
Receiving apparent problem exists with parts or container, paperwork before creation of Work Order.
for disposition by the Quality Dept. If necessary, All info noted on the shipper
parts are placed on hold pending disposition. and entered in WORP, shows blue for 2%
weight tolerance.
Related
Question Customer or Internal Job (Shop) Order or Reference Documentation Pass / Fail
Job Audit Question HTSA Actual Condition (Objective Evidence)
# Requirement Requirement / N/A
Question #
4.6 Are the Loading / Racking 1.6 Internal Work Order / Recipe defines Feedrate Feeding rate set at 1000#/hr on Pass
requirements identified? 2.7 Requirement of 1000 lbs/hr. computerized feeder and loading timing
2.9 (start/finish) was documented on WO.
4.7 Is the proper recipe or process 1.5 Internal Proper recipe is integrated when part number is Hard copy WO (shop traveler) was Pass
specification (cycle times, 1.6 entered into electronic (Worp) Work Order compared to the furnace setup and
temperature, atmosphere, etc.) 2.1 creation software during creation of shop Work settings.
used? Refer to Process 2.14 Order. Recipe does not have provision for adding
Tables, Section 3.0, for 2.15 additional steps to current WO. A hard copy of
specific parameters. List the WO is being used.
parameters that were verified
in this audit in the spaces
provided below.
Related
Question Customer or Internal Job (Shop) Order or Reference Documentation Pass / Fail
Job Audit Question HTSA Actual Condition (Objective Evidence)
# Requirement Requirement / N/A
Question #
4.8 What are the product 2.15
inspection requirements?
4.8.1 Requirement: Surface
Hardness as
Quenched
Test Method: Surface Internal ASTM E18. If specified, inspection photo defining Test results recorded in WORP and on Pass
Hardness sample preparation & location(s) for Surface hard copy of Work Order.
Testing Hardness testing.
Test frequency or quantity: Internal 5 pcs/hr, min 10 pcs/order 5 pcs checked at audit, 20 pcs total Pass
Selection of samples: Internal Random during hourly check Random during hourly check Pass
Specification: Internal No specification Actual: HRB 86.2 - 102.5 Pass
4.8.2 Requirement: Surface
Hardness as
Tempered
Test Method: Surface Internal and Customer ASTM E18. If specified, inspection photo defining Test results recorded in WORP and on Pass
Hardness sample preparation & location(s) for Surface hard copy of Work Order.
Testing Hardness testing.
Test frequency or quantity: Internal 5 pcs/hr, min 10 pcs/order 5 pcs checked at audit, 15 pcs total Pass
Selection of samples: Internal Random during hourly check Random during hourly check Pass
Specification: Internal and Customer HRB 84 - 110 Actual: HRB 85.6 - 95.6 Pass
4.8.4 Requirement: Total Case
Depth
Testing
Test Method: Total Case Internal Per J423: Sectioning part, acid-etching, then Test results recorded in WORP and on Pass
Depth visual measurement using Brinnel Scope scale. hard copy of Work Order
Testing
Standard
Test frequency or quantity: Internal 1 pc/ hr, min 3 pcs/order 2 pcs checked at audit, 5 pcs total Pass
Selection of samples: Internal Random Random Pass
Specification: Internal and Customer 0.003" - 0.010" Actual: 0.006" - 0.008" Pass
Related
Question Customer or Internal Job (Shop) Order or Reference Documentation Pass / Fail
Job Audit Question HTSA Actual Condition (Objective Evidence)
# Requirement Requirement / N/A
Question #
Operator or Inspector Responsibilities
4.9 Were appropriate process 1.4 Internal Work Order requirement for redundant signoffs. Electronic signoff of process steps in Pass
steps signed off? 2.2 WORP, as well as initialed on hard copy of
2.3 the WO. CN and Temper in Worp and
2.14 paper shop traveler at audit time.
4.10 Were all inspection steps, as 1.2 Internal Most of the Control Plan (CP), including Electronic recipe requires electronic & Pass
documented in the control plan 1.4 inspection criteria, is integrated into electronic manual signoff of each step, with final
performed? recipe in Worp software; a Generic Control Plan review & signoff by Shift Leader (or
has also been created to address other aspects authorized representative) or WO cannot
of Control Plans. be closed for shipping. All steps signed off
at the end of the job.
4.11 Were steps/operations 1.2 Internal Additional washing step can be performed at Shift No additional steps were performed. Pass
performed that were not 1.4 Leader's discretion, as allowed in AMP
documented in the control 1.6 documentation.
plan?
4.12 If additional steps were 1.2 Internal Internal Requirement that certain (critical) No additional steps were performed. If Pass
performed, were they 1.4 additional steps can only be authorized by the post-wash is performed, it is allowed per
authorized? 1.6 Quality Department. AMP documentation
1.11
1.17
4.13 Does the governing 1.11 No specification Rework of order requires Quality Department Call customer for rework approval. Pass
specification allow approval. Retempering is not considered rework.
reprocessing or rework?
4.14 If the order was certified, did 2.14 Internal and Customer Data on Certification and data on WO match; Certification Data matched the data in the Pass
the certification accurately 2.15 data is electronically generated. hard copy of the WO & the electronic copy
reflect the process performed? of the WO.
4.15 Was the certification signed by 1.17 Internal and Customer Certification automatically acquires & applies Certification electronically signed by Pass
an authorized individual? Quality Manager's electronic signature. Quality Manager.
4.16 Are the parts and containers 2.6 Internal and Customer AMP procedure requires visual inspection of parts Containers & parts were visually free of Pass
free of inappropriate objects or 2.11 & containers at Incoming and Outgoing. contaminants. Outgoing customer
contamination? containers inspected during audit.
CQI-9 3rd Edition Section 4 - Job Audit 16 of 24
CQI-9
Special Processes: Heat Treat Systems Assessment
Version 3, Issued 10/11
Section 4 - Job Audit Carbonitriding (CN)
Job Identity:
Customer: Non-Disclosure
Shop Order Number: WO 68671
Part Number: Non-Disclosure
Part Description: Non-Disclosure
Material: Per Customer print/specification
Heat Treat Requirements: Carbonitrided & Temper
Related
Question Customer or Internal Job (Shop) Order or Reference Documentation Pass / Fail
Job Audit Question HTSA Actual Condition (Objective Evidence)
# Requirement Requirement / N/A
Question #
Packaging Requirements
4.17 Are packaging requirements 2.9 Internal AMP requires that, upon completion of Heat- Process Steps were signed off on Pass
identified? Treating & Sorting, parts are returned to electronic & paper copies of Work Order
Customer's original containers and weighed, and each bin weighed out, with weights
weights recorded on Work Order. recorded. Shipping records and signed
shipper in WORP.
4.18 Are parts packaged to 2.9 Internal AMP attempts to package outgoing material as Parts were evenly distributed in the Pass
minimize mixed parts (for closely to incoming packaging as possible, by container and were not packed over the
example, parts packed over weight. height of the 1 container.
height of container)?
Shipping Requirements
4.19 Were the parts properly 2.3 Internal and Customer WO creation requirement to identify parts & Work Order Router Tag, identifying the Pass
identified? 2.9 container with AMP Router Tags, linking parts within the container, were attached
container to parts to AMP Work Order to to Customer containers.
Customer PO/Shipper.
4.20 Were the containers properly 2.3 Internal WO creation requires labeling of Customer Properly labeled AMP Router Tags were Pass
labeled? 2.9 containers w/Router Tags. attached to customer container.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater
is conforming to the customer's requirements.
Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.
OK - Complies to requirement
NOK - Does not comply to requirement (Explain noncompliance in 'Related HTSA Question #'
NA - Requirement not applicable
A1.3 1.18 A program for furnace and generator burnout is required (applies to carbon bearing atmospheres). OK
A1.4 3.2 Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum. OK
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon
A1.5 3.2 OK
potential in furnaces, shall be calibrated annually at a minimum.
A1.6 3.2 Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use. N/A
A1.7 3.2 Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum. OK
Oxygen probe controllers shall be calibrated quarterly (single-point or multi-point calibration) or semi-annual (multi-point calibration
A1.8 3.2 OK
only; single-point calibration not allowed).
All hardness test equipment (for each scale used) shall be calibrated annually minimum, and verified daily or prior to use, per the
A1.9 2.16 OK
applicable ASTM standard, ISO standard, JIS standard, or approved standard.
A1.10 2.16 Files for testing hardness shall be verified per the Customer requirement. OK
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified prior to use (with distilled water)
A1.11 3.2 N/A
and calibrated annually (per manufacturer's requirements) at a minimum.
CQI-9 requires a System Accuracy Test (SAT) check of all control thermocouples per Section 3.3. Also, any recording or monitoring
3.2 thermocouple(s) more than 5 centimeters from the controlling thermocouple in the zone, for example thermocouples in continuous belt
A2.3 OK
3.3 furnaces near the drop point to quench used for recording or monitoring the hardening temperature (this does not include the "over-
temperature" thermocouples that are used to protect the furnace from overheating).
TUS shall be performed annually and after major rebuild per Section 3.4
A2.4 3.4 OK
Temperature uniformity tolerance for hardening furnaces shall be +/- 15oC (or +/- 25oF). Temperature uniformity tolerance for
tempering furnaces shall be +/- 10oC (or +/- 20oF).
Recorded temperature(s) for austenitizing processes shall be controlled within +/- 10oC (or +/- 15oF) of the set point as evidenced by
continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as
A2.5 3.5 defined above). OK
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 5oC (or +/- 10oF) of the set
point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower
A2.6 3.5 tolerance limit (as defined above). OK
For Continuous Furnaces, this requirement applies to the Qualified Work Zone.
A2.7 3.2 Infrared pyrometers shall be calibrated annually using proper calibration methods or an approved manufacturer's procedure. N/A
Generators shall be
continuously
monitored and
alarmed. Other
1.4 systems, such as
A3.2 2.14 Monitor atmosphere generation as applicable. nitrogen-methanol OK
3.7 systems, may either
be continuously
monitored and
alarmed, or sign-off
every 2 hours.
1.4 Monitor load size or fixturing or loading rate, as Twice/shift & after any
A3.8 Each batch OK
2.7 applicable. change in loading rate.
1.4
A4.2 Surface hardness Each batch Every 2 hours OK
2.15
1.4
A4.3 Core hardness (when specified) Each batch Every 4 hours OK
2.15
1.4
A4.4 Case depth (when specified) Each batch Every 4 hours OK
2.15
Batch Continuous
5.0 QUENCHANT AND SOLUTION TEST FREQUENCIES OK / NOK / NA
Furnace Furnace
Polymer Quench Media N/A
2.12
A5.1 Concentration Daily Daily
3.14
Cooling Curve Analysis Semi-annually Semi-annually
2.12 Water Quench Media
A5.2 3.14 Suspended solids Semi-annually Semi-annually OK
2.12 Salt Quench Media N/A
A5.3
3.14 Analysis & Contaminants Semi-annually Semi-annually
Brine or Caustic Quench Media N/A
2.12
A5.4 Concentration and/or Specific Gravity. Daily Daily
3.14
Suspended solids Semi-annually Semi-annually
Oil Quench Media
2.12
A5.5 Water content, suspended solids, viscosity, cooling
3.14 Semi-Annually Semi-Annually OK
curve, total acid, and flash point.
Rust Preventive - Soluble Oil
A5.6 2.13
Concentration 2x / week 2x / week OK
Washers
Concentration of cleaner Daily Daily OK
A5.7 2.11
Temperature of solution (required if temperature is
Each shift Each shift OK
specified to be above ambient temperature).